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By P. Somasundaran, D. W. Fuerstenau

This article presents the results of an analysis of grinding of 1:1 mixtures of 4x8-mesh quartz and limestone in laboratory ball and rod mills. From these experiments, the amount of energy consumed in grinding each component of the mixture was determined. In the ball mill, limestone consumes slightly more energy than quartz in the initial stages of grinding, but as the grinding proceeds quartz begins to consume a slightly greater fraction of the energy. The postulate that the fraction of energy consumed by any material in a ball mill is proportional to its volume fraction has been shown to be approximately true. On the other hand, in a rod mill energy consumption by quartz and limestone is equal only in the initial stages of grinding, with energy consumption by quartz greatly exceeding that by limestone as rod milling proceeds. Preferential energy consumption in tumbling mills has been discussed in a number of papers. For example, from an analysis of the kinetics of comminu- tion in ball mills, Arbiter and Bhrany' obtained rate equations based on the postulate that only coarse particles are ground, indicating that fine particles are protected from the action of the balls by coarser particles. In rod mills this protective action is much more pronounced than in ball mills. Recent studies on the rod milling of limestone-quartz mixtures have shown that this protective action causes the mineral with the lowest grindability (quartz in this instance) to consume the greater fraction of energy. 2 However, in the ball milling of mixtures it has been postulated that the consumption of energy by one of the constituents is determined by its volume fraction within the mill. 3 Possibly this hypothesis may be a simplification of the ball milling of mixtures since the protective action suggested by Arbiter and Bhrany may result in some preferential energy consumption by one of the constituents of a mixture. The objective of this study has been to determine preferential energy consumption in laboratory ball and rod mills by analyzing size distributions of each material in the products obtained from grinding 1:l mixtures of quartz and limestone. MATERIALS AND METHOD The procedure for carrying out the tests on wet grinding quartz-limestone mixtures has already been described.'r3 In the present investigation, 1:l mix-

Jan 1, 1963

By K. Boakye

This paper presents the results of a review of historic blast design practices at the Dragon Products Company, LLC (Dragon) Quarry Operation, along with the results of two different blast design vibration monitoring programs. A blast pattern design modification was initiated to determine if production volume per shot could be increased and highwall instability could be decreased. A vibration monitoring program was undertaken to investigate peak particle velocity (PPV) and relate the data to the blastability of the jointed onsite rock mass, utilizing the relationship between PPV and dynamic stress and strain. The Dragon Quarry Operation has historically used a 6-in. diameter, 14-ft by 14-ft production blast pattern, with blast holes loaded manually using cartridge style explosive products. In 2011, Quarry Operations introduced a 6-in diameter, 16-ft by 16-ft production blasting pattern, using pre-mixed, truck-loaded, bulk emulsion/ammonium nitrate/fuel oil (ANFO) blends. This paper summarizes the results of the blast design modifications, the results of the vibration monitoring data, and describes how production blasting and excavation at the Dragon Quarry has benefited from such modifications.

Feb 27, 2013

The effect of composition on electrical conductivity (resistivity), viscosity and liquidus temperature of the slags encountered in electric smelting of PGM-containing suphide concentrates is reviewed along with the relationsip between slag composition, slag-matte separation and metal losses to slag. Optimization of slag composition at furnace temperature is attempted on the basis of opposite and parabolic trends of the viscosity-conductivity relationships of the slags. The importance of surface tension of slags is emphasized using available and estimated information, which are grouped into a useful correlation. These values are coupled with or incorporated into slag viscosity plots to illustrate the correlation between the two factors which influence slag-matte separation as well as refractory attack. The electrode in the slag-resistance furnace is the central factor in the design and operation of the furnace by its role of conveying the smelting power. The obvious parameters are the size and positioning in the slag bath, which are defined by slag resistivity, furnace resistance, cell constant and power input. The flow of heat generated by the electrode current determines the energy distribution and furnace dimensions creating viscosity profiles, which in turn affect flow conditions. Thus the flow of slag and matte isdiscussed in conjunction with the furnace geometry, stirring action of the electrodes, buoyancy and electromagnetic effects. The action of the electric furnace as a settler is discussed. The rectangular furnace is considered as a channel reactor in this analysis and the action of the electrodes is described to indicate a balanced settling rate in the area of electrode action. Discussion of the design and production capacity of the electric furnace with reference to operating current, power input, furnace dimensions and electrode size are based on considerations derived mainly from slag properties such as its resistivity, viscosity and liquidus temperature.

Jan 1, 2004

By H. Warren Newcomen

Assessments of the stability performance of open pit highwalls have traditionally been based on consideration of surface movement rates. Although generally accepted in industry, this approach presents challenges for establishing appropriate threshold values to allow for safe mining operations and does not address the issue of total strain. Surface movement monitoring data from a limited number of open pit mining operations in North and South America has been evaluated in terms of highwall strain, rock mass quality and inferred mechanism of instability. Threshold strain levels for key stages of highwall stability proposed from previous work have been reviewed and are generally endorsed based on evaluation of additional data. An empirical highwall strain criteria for the assessment of highwall stability performance is postulated based on the observed trends in highwall strain data from the case histories presented.

May 1, 2004

By Wenbing Xie

At Renlou Coal Mine, Huaibei Mine Area, the track entry deformed significantly after longwall mining in an overlying multiple seams. The supporting characteristics of primary roof bolts and shotcrete with wire mesh are closely related to the movement of the mine?s surrounding strata. A case study of a track entry deformation was monitored during the longwall mining of a selected overlying panel. The measured data showed the unique entry deformation pattern during the longwall mining in the overlying seam. Underground extensometer measurement showed that entry stability was mainly affected by the periodic roof weighting of longwall mining in the overlying seam. The displacement of the deeper strata occurred a head of the immediate vicinity of the entry. Thereafter, deformation of the roof and floor strata was in the form of shearing of the shallower strata. Due to the use of heavy-duty roof bolting with wire-mesh, the roof-tofloor and rib-to-rib convergences were small, but the floor heave was large, greater than 80% of the roof-to-floor convergence. The measured displacement from extensometers varied with the position of the monitored cross-sections and depth into the roof. There were several deformation patterns, such as shearing movement, compression, and expansion, and the variations between compression and expansion. Strata compression at the entry surface was always accompanied with shearing movement at the deeper strata. During the longwall mining, the whole surrounding strata of the entry moved toward the opening. Underground practical experience indicated that prior to mining, the entry was supported very well in excellent conditions. After mining, however, it deformed greatly. The current entry support technology was not effectively control the severe deformation incurred in entries driven in soft strata due to the following reasons: (1) little is known about the entry deformation behavior of the strata surrounding the opening and (2) the degree of interactions between entry deformation and roof bolting with wire mesh is not well understood. Consequently, effective supporting systems cannot be properly selected to control its deformation and maintain a stable supported surrounding structure.

Jan 1, 2012

By Wen Tao Liu, Tong Tian, Fu Sheng Niu, Xiu Man Liang

In order to address the difficulty of accurate segmentation of froth images of different sizes, a method of froth image segmentation based on highlight correction and parameter adaptation is proposed. First, a machine vision system on a single-cell flotation machine is built to collect froth images. Homomorphic filtering is used to improve the uneven brightness and shadow of the images. Fuzzy c-means (FCM) clustering is then utilized to classify similar highlights that belong to the same froth. After Otsu threshold segmentation, a parameter-adaptive morphological operation is used to extract the marker points and edge bands and correct the froth edges in the original image. Finally, the modified image is filtered by morphological reconstruction, and the highlight mark is used as the local minimum point for watershed segmentation. Three sizes of froth images are segmented in comparative experiments. The results show that the proposed method is suitable for the segmentation of froth images of different sizes. The position of the extracted segmentation line is close to reality, with average over-segmentation and under-segmentation rates for froth images of 2.6% and 6.8%, respectively. The froth image segmentation performance is stronger than that of the other methods examined.

By T. M. Barczak, S. C. Tadolini

Reduction in the recovery time required and improvements in safety during a longwall face move have compelled coal mine operators to examine and use pre-driven longwall recovery rooms. The recovery entry is developed at the longwall stop position and supported ahead of time so that the required combinations of standing and internal supports can be installed before the longwall face approaches. A calibrated three-dimensional finite element model, developed in conjunction with an underground test area, provided the critical components and design principals for a comprehensive parametric study. The study indicates that vertical, horizontal, and shear stresses concentrated on the outby abutment pillar corner of the recovery room resulting in deformations in the immediate roof above the primary roof support anchorage level. The results of the numerical model and field site observations indicated that the combination of the internal bolting system and the standing concrete supports are critical for the successful and safe extraction of the longwall equipment. Cable supports installed at and angle over the pillars can help stabilize the disturbed zone above the adjacent fender and outby pillars, however; standing supports are required in most sedimentary roof conditions to increase stability and assure a safe longwall extraction.

By Jacques J. Eksteen

Any effort to improve the metallurgical control of industrial furnaces employed in the primary extraction of high carbon ferroalloys are bound to fail unless the variability of the melt is not fully accounted for. A number of sampling campaigns were performed on both 3phase AC submerged arc and single phase DC open arc furnaces at different smelter sites in South Africa where High Carbon Ferrochrome is produced. It was found that the heterogeneity between multiple samples during a single taps were much higher that for heterogeneity found within a sample. Moreover, this heterogeneity (as quantified by the relative standard deviation per tap) varied with the operating conditions of the furnace, the element monitored and the type of furnace. A relationship was found between the relative standard deviation of certain elements and the degree of subcooling of the melt.

Jan 1, 2006

By S. Hunt, D. de Vries

Kansanshi Copper Smelter began operation in March 2015. The smelter features a single Isasmelt furnace for smelting, one 6-in-line electric furnace for matte-settling and slag-cleaning duties, four Peirce- Smith converters and two rotary anode furnaces. A 1,450 t/day oxygen plant and a 4,085 t/day sulphuric acid plant are included in the smelter operations. This paper gives an overview of the operational performance to date with summary data for each smelter section. Challenges such as an unforeseen refractory failure in the Isasmelt furnace in 2016 are discussed. Design improvements around the electric furnace are mentioned. Plans for potential future improvements are put into context. A consistent focus on operations, maintenance and continuous improvement has seen the smelter easily achieve its nameplate capacity of 1.2 million tonnes per annum of copper concentrate throughput. The smelter now operates consistently at a concentrate throughput rate of 1.38 million tonnes per annum of copper concentrate. INTRODUCTION The smelter was commissioned in March 2015. Design and commissioning of the smelter have been discussed by de Vries, Hunt, Hanschar and Louie (2016). The smelter rapidly ramped up to achieve nameplate production (1.2 million tonnes per year concentrate) and in 2018 operated consistently at the rate of 1.38 million tonnes per year concentrate. This paper presents major operational data for each section of the plant and describes significant events and improvements during the first four years of operation. The smelter flowsheet is shown in Figure 1.

Jan 1, 2019

By Timothy M. Bruner, William J. Maloney

Faced with rapid growth that strained their current water supply capabilities, the Somerset Water Service in Somerset, KY decided to construct a new intake structure on the shore of Lake Cumberland. With an existing intake structure within 200', very hard limestone geology with calcite geodes, and lake level fluctuations as high as 50 ' ,this project posed many challenges. The following paper discusses how mechanical excavation techniques were used to overcome these obstacles.

Jan 1, 2001

By J. Châteauneuf, R. Dupéré, D. Mrabet

"In gold processing plants, it is common to start gold cyanidation in the grinding circuit by simple cyanide addition or as a result of recycling residual cyanide. In such cases, advantages such as a decrease in gold lockup and reduced leach time have been noticed. The prevailing conditions in grinding circuits such as intense mixing, particle breakage and friction or high temperature are quite different from those found in tanks and so is the resulting cyanidation behaviour. To gain a better understanding of the cyanidation behaviour in mills and of the pertinence of cyanide addition in grinding circuits, lab tests were conducted using an industrial ore from Canadian Malartic mine. In this study, the effects of different parameters on cyanidation in grinding circuits were examined; parameters such as such as temperature, dissolved oxygen, cyanide concentration and pH. The results showed that the kinetic benefits of high temperature in the mill can overcome the low dissolved oxygen concentration thus leading to an overall gold dissolution kinetics improvement for temperatures up to 50°C. However, gold leach in the studied grinding circuit at lab scale caused an increase in cyanide consumption with a higher generation of iron cyanide and SCN-. These results were confirmed by tests in the Canadian Malartic plant where the cyanide addition was moved from the SAG mill to the leaching tanks resulting in a 20% savings in cyanide consumption.IntroductionCyanidation in grinding circuits can benefit gold processing by decreasing gold lockup and by reducing leach time. However, other aspects regarding gold and cyanicide dissolution come into play in the conditions prevailing in grinding circuits. Indeed, high turbulence, high temperature, recycling load, friction and particle breakage make cyanidation behaviour in grinding circuits different from in-tank cyanidation (Marsden and House, 2006). In several cases, cyanide in grinding is limited to a very low level or completely avoided such as in circuits with gravimetric separation, for ores requiring oxidative pretreatment or for preg-robbing ores. In other cases, water management imposes a certain recycling of residual cyanide. This problem is generally addressed by a case-by-case approach. However, the chemistry of cyanidation in mill circuits is worth investigating in order to assess the advantages and disadvantages."

Jan 1, 2016

By Michel G. Grenier

Compliance with Diesel Particulate Matter (DPM) exposure regulation is currently performed using timeweighted average (TWA) sampling on underground mine workers. These samples are collected in the span of an entire shift and the resulting concentrations are compared to a legislated exposure limit. While this is very useful to determine the exposure level of an individual to DPM, it fails to clearly identify causes of exposure and highlight opportunities that could help reduce the exposure of workers in the course of the work shift. Real-time DPM monitoring measures the worker?s exposure as a function of time and helps identify circumstances where corrective actions can be taken or design changes can be made by the individual or the employer to reduce the overall exposure of the worker and peers. This work focused on obtaining DPM concentrations using a real-time polycyclic aromatic hydrocarbon (PAH) monitor. The aim was to demonstrate that this instrument, while not a direct DPM analyzer, was able to provide a concentration profile that could easily be linearly correlated to standard TWA elemental carbon measurements. In addition, several instances of improvements that could be implemented to reduce the exposure of underground employees were demonstrated.

May 1, 2010

In New York City, on the walls of the library of the United Engineering Societies are these words:"Engineering-the art of organising and directing men and of controlling the forces and materials of nature for the benefit of the human race," but who, reading the schedules of even our best engineering schools, would infer that engineering is an art or that it should always havejn mind the benefit of the human race? While it must be remembered that our engineering schools exemplify the British cult of the amateur, that cult which lets men who have never attended a lecture on "Education" or perhaps nevereven read a book on it, become enginering teachers by profession (and so educators by inference), the root of the matter is to be found in the fact that our educational aims, and consequently our educational practice, seem suited much better to the position engineering held in the community in 1900 than to the position it holds to-day. This civilization of ours has developed, !;loth for good and for ill, into one based largely on engineering achievement; technical progress is so continuous and so rapid that thevalue of descriptive knowledge of current practice is ever lessening; enough must be imparted to make the young graduate immediately employable, and this amount is sufficient for illustrating the principles on which practice is based and on which its advance depends, but the young graduate's technical progress depends much less on his having acquired additional knowledge than on his ability to acquire knowledge, so, paradoxically, the more useful knowledge there is availabJe the less of it the student should be taught.Less conspicuous but fully as important is the enlargement of the field of work of engineering graduates, especially its extension to the initiating of policies and to the broader problems of administration. At present the road to such positions lies normally through a considerable period of professional work, but it is by no means unlikely that the field will soon include much that requires little professional expel'ience. At all events it is safe to say that the changed. and changing position of engineering in the communitydemands the attention of the engineering schools and that profitable discussion of engineering education demands some understanding of the real nature of education and of the part which engineering plays in the life of the community.THE NATURE OF EDUCATIONUnfortunately "to educate" supplies an example of how words degenerate in meaning; most people regard it as the equivalent of "to instruct"; a small number feel they have gone to. the root of the matter when they say...

Jan 1, 1941

By M. Yavuz

One of the challenging problems for optimization in mining operations is to choose the best equipment among the alternatives. Equipment selection is an important task for mine management due to its operational cost, and is also an integral part of mine planning and design. Equipment selection is not a well-defined process because it involves the interaction of several subjective factors or criteria. Besides, decisions are often complicated and may even embody contradictions. Therefore, equipment selection is considered as a multi-criteria decision-making process, and suitable decision-making methods should be employed in this process. In this study, the loader selection for Aegean Lignite Colliery was made by using both the analytic hierarchy process and Yager’s method. Owing to the misusage of Yager’s method in the past, a new procedure is proposed in this paper for making proper decisions. It is highly recommended in this purposed method that criteria or alternatives should be grouped so as not to exceed the limitations of human performance (nine criteria/alternatives). The most appropriate solution for the loader selection was investigated by obeying this limitation for each method, and the results were compared. At the end of the decision-making process, a sensitivity analysis was applied for each method in order to see how a criterion affects the final decision. The advantages and disadvantages encountered during the application of each decision-making method are presented.

Jan 1, 2015

The development of an onboard contaminant diagnostic monitor to continuously measure contaminant level in a mining machine was advanced to a prototype stage in this contract. Several concepts were investigated and it was found that a static spool type sensor was the most reliable and accurate. Laboratory and field tests showed that an instrument based on this concept is capable of measuring contaminant levels and/or size distribution, depending on the configuration of the sensor. Moreover, this instrument can function on emulsions or homogeneous fluids. Current laboratory equipment can operate on homogeneous fluids only.

Jan 1, 1983

By Glen D. Frank, Jeremy P. Theys, Mina M. Shinouda, Gary W. Gilbert

PURPOSE OF THE PROJECT The Big Walnut Augmentation Rickenbacker Interceptor project began in 1995with the preparation of the Scope of Services for the design of the Rickenbacker Interceptor, with service to and around the Rickenbacker Air Force base. The air base was soon to be placed under civilian control through a Port Authority, with an expected influx of businesses and services, requiring increased sanitary service capability. Due to political differences regarding annexation and other issues, the project was placed on hold. In mid 1996 the Scope of Services was rewritten with more emphasis on a tunneling option, but still only addressing the air base and surrounding tributary are a sanitary service requirements. The consultant selection process began in late 1996 with the Request for Statements of Qualifications issued in December. Three firms were selected to furnish proposals based on the revised Scope of Services that now included requirements for hydraulic modeling of the service areas and the Big Walnut Outfall (BWO) and an expanded soil investigation requirement. All three firms were requested to make presentations to the selection committee, with the committee selecting URS Greiner for further consideration and negotiation. A contract was entered into in August of 1997with URS Greiner. The major sub-consultants were Lachel and Associates, Inc., H.R.Gray and Associates and Solar Testing Laboratories, Inc. The project began with geological investigations, preliminary soil borings, well investigations, tributary area evaluations, hydraulic modeling of the BWO system and research into other projects planned for the Rickenbacker airport and surrounding area. The hydraulic modeling of the BWO and the proposed Rickenbacker Interceptor confirmed that the BWO suffered wet weather surcharging and would require augmentation to properly convey the future flows to the Southerly Wastewater Treatment Plant(SWWTP). The project scope expanded to include evaluation of both the Rickenbacker Interceptor and the Big Walnut Augmentation projects. Both projects previously identified in the Capital Improvements Program. The work on the expanded scope for the Big Walnut Augmentation and the Rickenbacker Interceptor began with the evaluation of a parallel 2.75 meter (108") diameter augmentation sewer from SWWTP to S.R. 317and Parsons Avenue, then continuing east along S.R. 317 as the Rickenbacker Interceptor. The parallel 2.75 meter (108") sewer had been planned for in the design of

Jan 1, 2007

By J. L. Fuentes-Cantillana, Á. Rodríguez, P. Morillo

Evacuation operations from work places in the case of an emergency are the key to minimising the effects of catastrophic type accidents such as fires, explosions, cave-ins, floods, etc. The correct planning of these operations, having the necessary means for sounding alarms and communicating and suitable training of personnel are the key factors for guaranteeing successful evacuation. The article gives an analysis of the problem in the case of subterranean mining and various types of work developed by AITEMIN in this field, including the development of new alarm and communication means specially adapted to the characteristics of mining operations, development of tools for help in the preparation of emergency plans and experiences in the education and training of personnel.

Jan 1, 2003

By Laurance A. Beck

Safety is the most important aspect of haul road design. Although other aspects of road installation enter decisions on design, the safety of persons using the road has to be foremost for the duration of haul road usage. Other aspects of mad design focus on minimizing truck cycle time and fitting haul roads to the long-term configuration of the mine/quarry or construction project. Roads are often installed at high gradients for a short-term goal, but the long-term benefits are easily shown with lower gradient haul roads which provide better cycle times and lower operating costs.

Jan 1, 1995

By Douglas Bartley, Jay Elkin

The state of Pennsylvania was at one time one of the leading coal producing states in the east. However, legislation and industry trends over the last 10 years have adversely affected the amount of bituminous coal mined in Pennsylvania and the whole eastern United States. The application for and approval of a new mining permit is a very costly and arduous task. When a new mining operation is established it is crucial that nothing within the operator’s control causes the operation to stop producing. This paper discusses the action taken by a small mine in Pennsylvania when their blast induced vibrations rose to levels that typically would have resulted in a total mine shut down by the regulatory body governing such operations.

Jan 1, 2003

By B. B. Broms

Embankment piles are common in the Scandinavian countries (Kjellman, 1940) and in Southeast Asia as support of fills, light structures, bridge abutments and deep excavations (Eide, 1968) as described in the following. Untreated timber piles are often used for light structures and shallow fills when the ground water level is high since they are inexpensive and readily available. When the applied loads are relatively high precast concrete piles and steel piles are preferred. DESIGN CONSIDERATIONS Embankment piles carry the load from a fill or a struc-ture either through skin friction along the sides of the piles (Fig. 1a) or through a precast concrete slab or through pile caps at the top of the piles (Fig. 1b). When the load is carried by skin friction it is often economical to use small diameter timber piles because of the large surface area (Asplund, 1939). For precast concrete or steel piles concrete caps are used to transfer the load to the piles due to the relatively high capacity of the piles since the skin friction resistance alone is not sufficient to transfer the load to the piles.

Jan 1, 2010